10 Tips From Shop Class You Should Never, Ever Forget

According to Shakopee West Junior High School, Chris Lyons is a "technology education teacher." I prefer the old nomenclature. Lyons is a shop teacher, one who's taught students (including my younger son) and adults about DIY tools and techniques. He's also the owner of CLyons Creations, where he crafts guitars and other woodworking projects.

Whether you're young or old, it's never the wrong time to sharpen your skills. So listen to the master.

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Make Clamps Your Friends

Brett Martin

Always clamp down your lumber before cutting, drilling, or routing. When you're in a hurry or just need to make a quick shave the edge of a piece to make it fit, it's tempting to hold onto the wood instead of taking the time to apply a clamp or two. But wood, and small pieces in particular, can move or even go flying when the blade or bit makes contact. That means you may not get the precise cut, hole, or edge you need, and you could get hurt.

"When a piece of wood moves, unless you're an experienced woodworker your first reaction is to jerk your hands away," Lyons says. "That's an accident waiting to happen. You could pull your hands right into the blade. Clamps take your hands out of the equation."

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Drill Pilot Holes Before You Drive Screws

Brett Martin

"When should you drill pilot holes? When you don't want the wood to split," Lyons says. "I have my students pre-drill holes for everything."

This is yet another thing that's easy to forego when you rush, but using an 1/8-in. or smaller drill bit to bore a small hole in the wood allows the screws to drive much smoother without the wood cracking or breaking. "It only takes a few seconds to pre-drill, but it takes a long time to replace split wood," he says.

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Measure Twice—With a Steel Rule

Brett Martin

Lyons takes his measurements with a steel rule, typically the one in his combination square. "With a steel rule, it's easy to hold the end flush against a piece of wood to get a precise measurement," he says. "Plus, the rule lays completely flat so you can see the numbers easily." Standard tape measures can wear out and get loose or bent, or get too much play in the end. Still, he keeps a tape handy. "For longer measurements when you need a standard tape, measure from the 1-inch mark instead of the end. Then subtract 1 inch from the final measurement. This will give you an accurate measurement."

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Use a Straight Edge for Cuts and Rips

Brett Martin

People who aren't used to crosscutting or ripping lumber have trouble keeping their circular saw moving along a straight line. Even when you have visible lines drawn on the wood, it's easy to get off course and bind the blade. This can leave burn marks on your lumber and even cause the saw to kick back, which is dangerous.

"Use a straightedge when making a cut with a saw or a router," Lyons says. "You can use anything straight for a guide, even another piece of lumber. Clamp it down and when you run your saw or router along it, you get a clean, straight line."

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Cut Angled Pieces a Little Long, Then Trim To Fit

Brett Martin

Cutting perfect angles in trim or other pieces of lumber can be tricky. The corners have to fit tightly together, so if the angle is even slightly off, you'll end up with a noticeable gap when the pieces are pressed together. To get a tight fit, Lyons recommends cutting the pieces about 1/8-inch longer than what you need.

"Cut it big and test-fit the angle," he says. "If it fits, it's easy to trim it back to the size you need. "If the angle doesn't fit together, you can trim it back a little at a time with your blade adjusted, or sand the corners to get the fit you need."

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Tap Into the Power of the Router

Brett Martin

"If I had to choose one tool to do almost anything with, it would be the router," Lyons says. "When you have a router, you have versatility, speed, and accuracy. You can do almost anything." A myriad of bits are available for different edges, while a router table lets you feed the lumber into the router bit instead of running the tool over the wood. For example, a router lets you cut fancy edges and patterns as well as dadoes and rabbets. You can also use it for making dovetails, mortises and tenons for strong joinery. "If you think you need a router, then you need a router," Lyons says.

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Start With a Detailed Plan

Brett Martin

A lot of people kick off their projects with a thumbnail sketch. Don't. Get a detailed plan drawn to scale that includes measurements, hardware, and materials, he says. When you look at the drawing, you should be able to determine the order of operation and how everything will go together.

"Details make the process go smoother. You see what the end result is supposed to look like, and it offers a better overall building experience," Lyons says. "Students in my class see the benefits of planning. You get enough surprises in a project. Good planning results in fewer surprises."

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Scour the Web

YouTube

In our hyper-connected world, blogs, how-to articles, and videos on every type of project and woodworking technique are a click away. "Whatever you need to do, somebody has already done it," he says. "You can learn from them and avoid mistakes."

Lyons, who's been making guitars for more than 10 years, still finds new tips online. "I can't believe what a resource YouTube is," he says. "My students and I have learned a lot by watching what other people have done. But also, know that nothing everything you see is a good idea. There's a lot of stupid stuff out there, too."

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Buy Quality Tools

Brett Martin

It's not a coincidence that Lyon's personal and school shops are filled with reliable, brand name tools. He buys tools for himself and his students that are safe, comfortable to use, and will last for a long time. "A good tool makes the job go easier," he says. Cheap tools are not really a value, despite their low price. "If it's a tool you'll use forever, spend the extra money. The last thing you want to do is buy a tool twice."

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Please, Keep Your Fingers

Brett Martin

Lyons says every shop teacher he knows has known someone who's missing at least one finger courtesy of a saw blade. That's why he and his ilk are so serious about safety. Listen to them.

In addition to basic safety measures like hearing and eye protection, Lyons suggests rolling up sleeves (not just pushing them up where they easily fall back down), keeping long hair tied back, and not wearing loose-fitting clothes. "If something on your body can get caught in a tool, it will. And if you have to ask if something is safe to do, then it probably isn't," Lyons says. "Never take shortcuts. They often lead to accidents. You also have to stay alert, especially during repetitive motion tasks. It's easy to take your eye of the project for a second, and that's long enough to cause an injury."

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